GMD1 - Section 07 - Tool Frames, Bases, and Robot Interface Equipment (Update 31JA22)

Global Mechanical Design Standards GMD1
Table of Contents
7. Tool Frames, Bases and Robot Interface Equipment ........................................................2
7.1. Introduction ________________________________________________________________________ 2
7.2. Production Tool Frames and Bases ____________________________________________________ 2
7.2.1. Custom Frames and Bases (Preferred - LEAN Solution) .............................................................................. 3
7.2.2. Frames or Bucks (Preferred - LEAN Solution) ............................................................................................... 5
7.2.3. NAAMS Bases (Alternative) ............................................................................................................................. 5
7.2.4. NAAMS Heavy Duty Bases (Alternative – Not Lean)...................................................................................... 6
7.2.5. Outer Skin Rest Fixtures or Hand-Off Bucks (GMNA only pending Global Approval) ............................... 6
7.3. Base Transportation _________________________________________________________________ 7
7.3.1. Integral Transportation Designed into Frame ................................................................................................ 7
7.3.2. Hoist Rings ........................................................................................................................................................ 7
7.3.3. Fork Pockets ..................................................................................................................................................... 9
7.4. Precision Finishing _________________________________________________________________ 10
7.5. Controls Equipment for Production Frames and Bases ___________________________________ 11
7.6. Production Tool Base Set-up (for other than horizontal) __________________________________ 11
7.6.1. Tool Adjustment for Turntable Applications (GMNA and GMIO only pending Global Approval) ............ 12
7.7. Weld Washers and Coordination Holes for Bases _______________________________________ 14
7.8. Leveling and Anchorage ____________________________________________________________ 16
7.8.1. Low Profile Bases - C-Flex Group ................................................................................................................. 16
7.9. Robot Adaptor Plates, Base Plates, and Risers __________________________________________ 18
7.9.1. Robot Cable Support ...................................................................................................................................... 19
7.9.2. Robot 7th Axis Floor Clearance..................................................................................................................... 20
7.10. Geopallet Common Hole Pattern for Underbody Tool Mounting ___________________________ 21
7.10.1. Large Geopallet Pin Clamp Orientation ...................................................................................................... 25
7.10.2. Small Geopallet Wire Management ............................................................................................................. 28
7.10.3. Large Geopallet Selection Criteria .............................................................................................................. 29
7.10.4. Pallet Transport Cart .................................................................................................................................... 30
7.11. Standard Weld Joints ______________________________________________________________ 31
7.12. Gusset Placement _________________________________________________________________ 32
7.12.1. Gusset Design for Standard Tube Construction ........................................................................................ 33
7.12.2. Gusset Design for Cantilever Tube Construction ...................................................................................... 34
7.13. Pierce Unit Mounting ______________________________________________________________ 35
7.14. Weld Gun Mounting (Incline Adjustment) _____________________________________________ 36
Tool Frames, Bases, and Robot Interface Equipment

Update 31JA22 Page 1 of 36
Section 7
See Web Site for latest revisions
7. Tool Frames, Bases and Robot Interface Equipment

7.1. Introduction
This section outlines the standards for Tool Frames, Bases, and Weldments. This section also provides
ordering codes and sizes for GM standard robot adaptor plates, base plates, and risers. Other
guidelines mentioned in this section pertain to transportation, machining, leveling, and loading of frames
and bases.
7.2. Production Tool Frames and Bases
The purpose of a tool frame or base is to provide a stable foundation for components of a tool, which
maintains the dimensional relationship of tooling components to one another.
The overall size of a frame or base should be minimized. The component footprint should always be as
small as possible to allow improved accessibility for operator loading and maintenance.
A general rule to apply is: The size of the primary fixture frame or base should be smaller in profile than
the largest part or sub-assembly contained within the tool. Any component of a fixture that occupies
space that exceeds the perimeter of the piece-part is non-value added space in the assembly plant.
Think of the overall shape of the tool as a trapezoid . The first component of a fixture design, the
frame or base, should set the example for the entire tool. The first choice for this type of construction
should be to utilize a current NAAMS or local standard component, keeping in mind that the size should
be minimized.
Below are several examples of the trapezoid concept. The first is a Geopallet that shows the units
extending beyond the transfer mechanism. The second example is a GEO fixture where multiple units
extend beyond the base to locate the sheet metal parts.
Geopallet Example: GEO Fixture Example:
Floor
“New Design
Standards”

Section 7
7.2.1. Custom Frames and Bases (Preferred - LEAN Solution)

Custom Frames and Bases are the preferred Lean Common Solutions. This approach supports the
trapezoid strategy and the “Design for the Application” philosophy. These frames must be designed
with structural tubes, angle brackets and C-channel members to ensure a 3:1 safety factor.
Machined pads for unit mounting should be sized to accommodate all of the units in a localized
area. There are three different acceptable solutions for unit mounting:
• Localized Pads for low unit density
• Localized Pads with a partial plate for tools with medium unit density
• Continuous plate for tools that have a high unit density
Mounting plate thickness shall be 1 ½ times the diameter of the largest fastener securing
components or assemblies on the tool. This requirement is the finished machined pads or plate.
The tool’s Center-of-Gravity must be considered during design to ensure that the tool will not fall
over prior to being lagged to the floor. This is critical during the build, integration and installation
phases of the project.
Hoist Ring Hole
Leveling Jack
Hole
Example of a Custom Tool Base

Section 7
When an operator’s walk path presents a trip hazard with base mounting to the plant floor, the
mounting pads must be relocated to eliminate the hazard. When a leveling pad has been removed
from the design, it may become necessary to add an internal leveling feature to compensate for the
removed pad.

Section 7
7.2.2. Frames or Bucks (Preferred - LEAN Solution)

Another Lean Solution is found in Section W of the NAAMS web site. When a tool design does not
require a custom frame or base solution, these simple frames are sufficient. These components
range in a wide variety of height, widths, and lengths. Please review anchoring specifications
located within the NAAMS web site at http://www.naamsstandards.org/.
NAAMS Two Leg Pass/Load Stand NAAMS Four Leg Pass/Load Stand NAAMS “U” Style Pass/Load Stand
7.2.3. NAAMS Bases (Alternative)

NAAMS has also created a series of Lightweight Bases ranging in size from 500mm x 1200mm to
1700mm x 1800mm. These bases are not “Designed for the Application” and often exceed the
trapezoid rule where the part is the largest shape of the tool design. If a lightweight base supports
the trapezoid rule, then the GM Zone Engineer must approve the use of these bases. Please
review anchoring specifications located within the NAAMS web site at
http://www.naamsstandards.org/.

Section 7
7.2.4. NAAMS Heavy Duty Bases (Alternative – Not Lean)

Heavy Duty NAAMS bases range in size from 1200mm x 1200mm up to 2400mm x 3600mm.
Similar to the light weight NAAMS bases, the Heavy Duty Bases may only to be used when this
solution supports the trapezoid rule and the “Design for the Application” philosophy. A design
source must obtain agreement from the GM Zone Engineer to include a Heavy Duty Base in a tool
design. Please review anchoring specifications located within the NAAMS web site at
7.2.5. Outer Skin Rest Fixtures or Hand-Off Bucks (GMNA only pending Global Approval)
Suction Cups shall be used for all outer skin Rest Fixtures or Hand-off Bucks rather than rubber
bumpers. The suction cups disperse the weight of the panel over the entire cup surface and do not
require air to hold the part in place. This design practice results in less damage to the outer panel
as compared to rubber bumpers.

Section 7
7.3. Base Transportation
7.3.1. Integral Transportation Designed into Frame

The most cost effective, lean solution to move body shop tooling is to design the frame with integral
pick-up points. The integral pick-up point should allow for movement with a fork truck or Broderson
Crane without the need for hoist rings or fork pockets. This concept would allow the tool to be
clamped to the forks for transfer (if necessary) or the use of slings / chains to move the tool.
7.3.2. Hoist Rings

If a component must be added to the design, then hoist rings are the preferred Lean Solution for
moving tools in our facilities. When hoist rings are incorporated in the design, the frame must be
designed so that it will not deflect during transportation. Consideration must be given to the
placement of units to avoid interference with slings, chains, etc.
HOIST RING (4 PLACES)
LIFT POINT
CHAIN, SLING, ETC.
HOIST RING SIZE TO BE

DETERMINED BY WEIGHT
PATH MUST CLEAR TOOLS THAT IS BEING MOVED
VIEW IN DIRECTION OF ARROW "A"

Section 7
Spreader bars may be required to ensure that the chains / slings do not damage the tool as it is
transported at the integration source or final production facility. Spreader bar lifting capability ranges
from 2.5 tons up to 50 tons. It is the responsibility of the System Integration and the Tool Installation
Contractor to provide the correct spreader bar if required.
Example of a Custom Tool Base
The tool transferring information above must also be considered at the tool unit level for construction
purposes.
If a particular tool unit has unique features that make transferring reasonably unsafe by usual methods,
design activity may incorporate additional lifting components as shown for bases. These additional lifting
component details shall be discussed during the Start of Design Gate or during the concept stages of
that tool and unit. The key is to allow for sufficient time to incorporate the necessary features without
delaying tool design delivery timing.

Section 7
7.3.3. Fork Pockets

If a tool design requires fork pockets, the GM Zone Engineer must be informed prior to design release.
When a base/frame requires the use of fork pockets, the pockets must be designed as part of the
structure. The fork pockets can be the entire length of the base if required. This pocket must provide
structural integrity to the base. Some frames structures can add fork pockets by simply utilizing pieces
of tubing, rather than designing with a single tube for the entire length, thereby reducing material costs.
The design activity shall determine the best approach to satisfying this requirement, so long as the tool
remains safe for transfer.
For tools that require fork pockets there are two basic design solutions.
Tools less than 3,600kg - the maximum distance between the fork pockets is 1,130mm.
Tools greater than 3,600kg but less than 9,100kg - the maximum distance between fork pockets is
1245mm.
For good tool balance, the distance between the fork truck pockets should be made as large as possible
within the limits indicated.
Do not close the back end of a fork pocket. Closed pockets create a hazardous condition because this
forces the truck operator to carry the tool on the ends of the forks.
610mm MIN.
1130mm MAX.
250 MIN.
100 MIN.
FORK POCKET FORK POCKET
Fork pocket Designs for a maximum of

3,600kg Tools
710mm MIN.
1245mm MAX.
300 MIN.
100 MIN.
FORK POCKET FORK POCKET
Fork pocket designs for tools over

3,600kg and up to 9,100kg maximum

Section 7
7.4. Precision Finishing

Only finish surfaces that require precision. For example, a mounting surface for a locating unit, slide
mechanism, etc. must have a precise mounting surface.
A mounting surface for a rough locator or part drop-off nest that is attached to the tool base or frame
does not require precision. In this case, a tapping plate may be the most cost-effective solution. The
mounting holes and surface of the unit are pre-machined in the tapping plate before the plate being
welded to the base or frame.
When detailing the frame, the dimensions of the hole pattern in the plate must be provided from the edge
of the plate rather than from the O-lines of the frame weldment.

Section 7
7.5. Controls Equipment for Production Frames and Bases

Refer to GMD1 Section 2 for controls component placement guidelines.
7.6. Production Tool Base Set-up (for other than horizontal)
Establish primary surfaces of production tool bases on even millimeters body grid lines.
When tooling requires angular positioning of body parts for welding or other reasons, keep base
surfaces parallel to body grid lines and let the base supports provide the tip position required as shown
below.
Any deviation requires the GM Manufacturing Engineer’s approval.

Section 7
7.6.1. Tool Adjustment for Turntable Applications (GMNA and GMIO only pending Global
Approval)
Turntables that contain two or more identical tool sets for the same operations (Multi Tools) and
have robotic interface must provide adjustment for complimentary tool set. This adjustment will
enable a single robot program for all common identical tool sets on a turntable. The single robot
program enables faster robot programming / recovery when required. Each tool will be certified to
itself as described in GTC1 Section 07. The adjustability of these tools enables movement of the
complimentary tools to an identical location relative to the interacting robots.
This adjustment must be for the entire tooling frame relative to the turntable frame. The current
design direction is the use of jack screws and oversized holes. To position the tooling plate, the
jack screws shall be attached to the frame. Below is a graphical representation of the four
locations of the jack screws. Two are for vertical adjustment and two are for horizontal
adjustment.

Section 7
Oversize holes in the tooling frame provide the necessary clearance for the macro movement.
The diameter of the oversized holes must allow 6mm of movement in any direction. The graphic
below identifies the mounting hole location and the oversize hole requirement.
The third plane of adjustment will be accomplished with construction spacers. The complimentary
tool set attachment points must include a construction spacer (precision plate) that off-sets the
tooling frame from the turntable frame. Again 6mm of adjustment is required for the third plane of
adjustment.
After final certification in the production facility, the adjustment points must be welded to eliminate
movement during normal operations. Fitting spacer plates must be used to eliminate the load on
the jack screws.

Section 7
7.7. Weld Washers and Coordination Holes for Bases

Line Blocks shall not be utilized on Body-in-White (BIW) Tooling.
Weld Washers with a flatted side will be utilized in place of Line Blocks or V-grooves. The flatted side of
the washers must be perpendicular to the outermost horizontal edge of bases, frames etc. Mount these
washers in a horizontal plane wherever possible. If there are no perpendicular edges, utilize two
washers in line to allow tool alignment to marked floor lines.
Weld washers shall be placed at the centerline of tool, or as close to center of tool as possible. There will
be sufficient space around the weld washer (100mm x 100mm) wherever possible, to assist in alignment
to body shop floor markings.
Symmetrical tools / bases

Symmetric tools must have one pair of the weld washers offset from the centerline. This will eliminate
the ability to improperly install the tool during integration or plant installation. The will allow the tool to be
installed correctly the first time.
Dispense equipment shall be dimensioned to the tip (nozzle). These dimensions will be located in the
system layout sheet 2A – Tool and Equipment Set-up. Therefore, weld washer are not required for the
supporting boom structure. The boom, controller and pumps should be located outside the perimeter
safety fence.

Section 7
All critical in-line multi transfer applications, (ex, overhead tool–to-tool, lift and carry systems), shall be
aligned utilizing laser technology. Primary tool gauge features, benchmark targets, and coordination
holes qualify for laser alignment applications, based upon certification information.
Actual measured bodyline coordinate values must be stamped at all base coordination holes during the
certification process. These measured values shall be tied directly back to the Tool Nominal Locating
Pin (TNLP). See Section 7 of Global Tool Construction (GTC1) standards for Tool Certification
Specifications. Do not identify any of these values on tool design drawings.
Coordination holes are used to aid in tool certification by providing a known, precise location in which to
mount certification targets or dowels. For a typical welding fixture, a minimum of (4) coordination holes
are required. Each coordination hole is 12mm diameter with a F7 tolerance.
Do not finish surfaces where non-critical tooling exists.
ACTUAL MEASURED VALUE
COORDINATION HOLE (REF.)
HOLE SIZE = 12mm F7
X4
2100
X3
-900
X2
X1
X1

Section 7
7.8. Leveling and Anchorage

Tools that contain CNC machined details require certification. Tools that are certified must use
leveling screws and leveling plates. Certified tools shall not be lagged directly to the floor, as doing
so can distort the frame or base. Utilize the tool leveling provisions outlined in NAAMS at
If a tool is NOT certified, no leveling feet are required.
7.8.1. Low Profile Bases - C-Flex Group

A Low Profile Base is a thick steel plate that is adequately supported by leveling screws. Low profile
bases can be used only when the following conditions are met:
C-Flex units are being mounted to the base. Ergonomic conditions are not acceptable when
designing to standard base heights (Approx 250mm or 10”).
The application of a Low Profile Base is approved by the GM Manufacturing Engineer.
Low Profile Base design guidelines:
• Base plate after machining is a minimum of 32mm thick.

• The length and width of the base are to be determined during design and should not be
larger than necessary.
• Because the base is a steel plate and not a ridged weldment, it requires more support than
a standard base. Leveling screws are to be placed around the perimeter of the base at
intervals between 500 and 1200mm. Internal leveling screws are to be placed such that
they are between 500 and 1200mm away from the next nearest leveling screw.
The plate is to be leveled using standard leveling techniques. See the leveling specifications
located within the NAAMS web site at http://www.naamsstandards.org/.

Section 7
All manual load stations shall maintain a minimum of 100mm between the floor and the bottom
plate of the tool. This is compliant with the BIW Ergonomics Worksheet that requires the necessary
Foot / Toe Clearance.
TOP OF
BASE
100mm (Approx)
In some instances, a set screw can be used in place of a NAAMS leveling screw. This allows
tooling to be mounted over a leveling screw. This method is to be used only when no other choice
is available and must be approved by the GM Manufacturing Engineer.
Top of Base Tooling on Top of Base
Set Screw Set Screw below flush
For Low Profile bases, hoist rings will be included in the design and are to follow the guidelines
described above in this section. In addition, hoist rings must be placed in such a way as to reduce
the amount the base plate will deflect during transportation.
Reference this section for guidelines to locate on Low Profile bases.
Low Profile Base designs will follow all other standards regarding machining, final assembly and
finishing in this section.

Section 7
7.9. Robot Adaptor Plates, Base Plates, and Risers

All Fanuc robots shall use the details captured in the table below. These details have been released in
Team center Automotive Engineering (TcAE) database and are available with detailed drawings sheets
included within the dataset / NX file. Robot risers taller than 1500mm require approval from a
Professional Engineer. This ensures that the design comprehends all of the forces that are applied to
the risers in both the operating and E-Stop conditions. The design source must contact the robot
manufacture to obtain Forces and Moment for both cases (Operating and E-Stop conditions).
Robot anchoring specifications are shown on all individual Robot Riser and Robot Base Plate drawings
and shall not be substituted. A qualified OEM Anchor supplier and the Body-in-White (BIW) Enterprise
have approved these specifications.
MA Detail
Fanuc Robot Model: Riser Size:
Number:
R1000iA Base Plate MA802715S
R1000iA 300mm Riser MA802716S Global 3 Global 4
R1000iA 600mm Riser MA802717S
R1000iA 900mm Riser MA802718S ARC Mate 120iC ARC Mate 120iC
R1000iA 1200mm Riser MA802719S R-1000iA/100F R-1000iA/100F
R1000iA 1500mm Riser MA802720S R-2000iB/125L R-2000iC/125L
R2000iA/R2000iB/R2000iC MA152514S R-2000iB/165F R-2000iC/165F
Adaptor Plate
except R-2000-iC/210L MC003690S R-2000iB/185L R-2000iB/185L
R-2000iC/210L Adaptor Plate No standard R-2000iB/200R R-2000iC/210L
R2000iA/R2000iB/R2000iC * Base Plate MB268623S R-2000iB/210F R-2000iC/210F
R2000iA/R2000iB/R2000iC 300mm Riser MB268625S R-2000iB/220U R-2000iC/210R
R2000iA/R2000iB/R2000iC 600mm Riser MB268626S R-2000iB/250F R-2000iB/220U
R2000iA/R2000iB/R2000iC 900mm Riser MB268627S R-2000iB/250F
R2000iA/R2000iB/R2000iC 1200mm Riser MB268628S M-900iA/260L M-900iB/280
R2000iA/R2000iB/R2000iC 1500mm Riser MB268629S M-900iA/350 M-900iB/280L
M900iA – 260L / 350 MA152511S M-900iA/400L M-900iB/360
Adaptor Plate
M900iB – 280 / 280L / 360 MC003691S M-900iB/700 M-900iB/400L
M900iA-260L / 350 / 600 M-900iB/700
Base Plate MB268624S
M900iB – 280 / 280L / 360 M-2000iA/900L M-2000iA/900L
M900iA – 260L / 350 / 600 M-2000iA/1200F M-2000iA/1200F
300mm Riser MB268625S
M900iB – 280 / 280L / 360 M-2000iA/1700L M-2000iA/1700L
M900iA – 260L / 350 / 600 M-2000iA/2300 M-2000iA/2300
M900iB – 280 / 280L / 360
M900iA – 260L / 350 / 600
M900iB – 280 / 280L / 360
M900iA – 260L / 350 / 600
M900iB – 280 / 280L / 360
M900iA – 260L / 350 / 600
M900iB – 280 / 280L / 360
M900iA – 600 MA152512S
Adaptor Plate
M900iB – 400L / 700 MC003706S
M900iB – 400L / 700 Base Plate MB268630S
M900iB – 400L / 700 300mm Riser MB268631S
M900iB – 400L / 700 600mm Riser MB252017S
M900iB – 400L / 700 900mm Riser MB252018S
M900iB – 400L / 700 1200mm Riser MB268632S
M900iB – 400L / 700 1500mm Riser MB268633S
* R-2000iC/210L requires a clip to be welded to the rear of the base plate to allow room for the middle
anchor to the floor.
Due to the size and unique application for the M2000, the standard robot adaptor plates, base plates,
risers have not yet been developed. Each supplier must design their own components (adaptor plate

Section 7
and robot riser) for their particular applications. For all robot risers, the supplier must obtain a PE
approval for their design.
7.9.1. Robot Cable Support

Robot cables shall be supported for any application that requires a riser tall than 600mm. The weight of
the robot cables causes stress on the connectors. The Unistrut support eliminates stress on the robot
connectors. Unistrut “T” brackets are attached to the riser by a tapping plates. Tapping plates included
in the detail drawings. GTC1 Section 2.4 provides dimensions for each cable support for all robot risers
(600mm to 1500mm).
Do not re-file, “Save –As”, or execute any TcAE functions associated to these files within the TcAE
database. If revisions must be made to any of the files below, contact the GM Manufacturing Engineer
for notification and execution.
Robots shall be located with sufficient room between the fence and the cables to provide access for
maintenance. The minimum recommended distance between the robot base / riser is 450mm to the
perimeter guard. Additional space may be required based upon the robot path.

Section 7
7.9.2. Robot 7th Axis Floor Clearance

The robot 7th axis rail shall be mounted with a minimum clearance of 60mm between the lower rail and
the floor (deck). This clearance is required to allow robot cables and connectors to be routed under the
7th axis rail.

Section 7
7.10. Geopallet Common Hole Pattern for Underbody Tool Mounting

The standard, common hole pattern was derived from a study that covered a range of architectures as
small a Gamma to as large as Lambda. This hole pattern is applicable to UB Marriage, UB Respot,
Framing, and Framing Respot lines.
To ensure future flexibility in GM’s manufacturing system, the geopallet hole pattern shall be identical
regardless of the designer of the pallet or tooling requirements. The sketch below is an example of the
hole pattern when placed on a pallet that is used on a large geopallet conveyance.

Section 7
Each geopallet contains a Tool Nominal Locating Pin that shall be identified in both the tool design and
processing documentation (Process Designer / eBOP). The pallet datums shall also be identified in the
tool designs with body lines.
For small geopallets, body lines dimensions shall be identified in the pallet tool designs. These body lines
are critical for certifying each geopallet.
Below are examples of the body lines and TNLP callouts for the small geopallet system.
655
655
1035

Section 7
Below is an example of calling out a TNLP in the Tool Designs. This information is necessary for
tool certification.
TNLP
X=2117
Y=-400
Z=263
Below are examples of the body lines and TNLP callout for the large geopallet system.

Section 7
TNLP
X=497
Y=-600
Z=-87

Section 7
7.10.1. Large Geopallet Pin Clamp Orientation
The pin clamp designs for all large geopallets shall be based upon the BODYUB-32
Manufacturing Requirement. The hole size requirements and location are captured in this MR
(see below).
BODYUB – 32 Manufacturing Requirement
All large geopallets the pin clamp orientation shall match the following Manufacturing
Requirements:
• BODYMC-23
• BODYMC-47
• BODYUB-71
• BODYUB-77
Prior to designing pin clamps for a new large geopallet, the GM Manufacturing Engineering shall
obtain the latest version of the four MRs to confirm the direction has not changed. In addition, the
GM Manufacturing Engineering shall obtain the latest CDLS file to confirm which pin clamps are
geo set (0.1mm undersized) and which are repot pin clamps (0.3mm undersized).

Section 7
For #1 Gage Hole, BODYMC-47 states that the diameter of the locating hole is 25.1mm. The pin
clamp hook shall be designed so that it can close away from the centerline of the underbody
(outboard).
For #2 Gage Hole, BODYMC-23 states that the diameter of the locating hole is 40.1mm. The pin
clamp hook shall be designed so that it can close away from the centerline of the underbody
(outboard).

Section 7
For #3 Gage Hole, BODYUB-71 states that the diameter of the locating hole is 40.1mm. The pin
clamp hook shall be designed so that it can close forward towards the FOL of the vehicle.
For #4 Gage Hole, BODYUB-77 states that the diameter of the locating hole is 25.1mm. The pin
clamp hook shall be designed so that it can close towards the FOL of the vehicle.

Section 7
7.10.2. Small Geopallet Wire Management

All small geopallet designs shall incorporate a covered aluminum cable tray to protect the wiring as
shown in the following pictures.

Section 7
7.10.3. Large Geopallet Selection Criteria

Large geopallets are available in four different levels of precision as described in the following
chart.
Bed Type Precision Where Used

Type A +/- 0.1mm, x, y, z coordinats geo set stations, motor rail position and weld, mig weld, flexible
measurement, and some vision stations (Perceptron, Banner,
Matrox, etc.)
Type B +/- 0.5mm, x, y, z coordinates respot stations
Type C +/- 0.5mm in x, +/- 2mm in y, +/- in manual process stations, idle stations
1mm in z
Type D non-precision operation non-process areas, primarily overhead delivery
For more detailed information, refer to the Comau Geopallet Standard Products file located in
GMSupplyPower.
When package protecting for future tooling, the bed type shall be specified.

Section 7
7.10.4. Pallet Transport Cart

Mud flaps shall be added around the pallet transport to allow the ATUs to detect the carts. The
mud flaps shall be 100mm (4”) wide and hang with 50mm (2”) of clearance to the floor. The mud
flap shall be secured with M8 fasteners and nuts. Because this cart can be moved throughout the
body shop, Nylon patch thread lock shall be used to ensure the mud flaps do not vibrate loose.
Use M8 fasteners
Angle bracket to
attach to the cart 6mm (¼”) thick
Neoprene Rubber
6mm (¼”) thick steel

plates attached to the All sharp corners
bottom as a weight shall be broken
The mud flaps shall be attached to the cart on 500mm (20”) centers. If the geopallet wheels are
inset less than 100mm (4”), then the wheels can be detected by an ATU. If the wheels are inset
more than 100mm, then the 500mm spacing rule applies to the entire side of the geopallet cart.
Mud flaps shall be placed

within 25mm (1”) of the corners
500mm (20”)
typical
50mm (2”) of clearance to

Wheels can take the place of the the floor
mud flaps as long as the overhang
does not exceed 100mm (4”)

Section 7
7.11. Standard Weld Joints

Do not closeout tube ends
Avoid the following weld joint designs:
Miter Joint: Butt Joint:

Section 7
7.12. Gusset Placement

When using a gusset to reinforce tube construction, the gusset must overlap both tube ends and provide
sufficient length for a fillet weld (see below). A gusset placed in such a manner will provide strength to
the joint without causing any welding issue. Below are two examples of gussets that provide superior
strength and minimize the bean deflection. The first example is for a standard welded tube construction
where the design requires additional reinforcement. The second example is for a welded tube
construction tube with a cantilever load.
For the computer analysis below, a standard tube construction (50mmX50mmX6mm) was used to
identify the preferred solution. The force was applied 500mm from the joint intersection.
BASE Line Analysis

Section 7
7.12.1. Gusset Design for Standard Tube Construction

Tube construction designs that require additional support should use a 450 gusset on one side of
the joint to strengthen the welded joint. If additional support is required, a second gusset on the
opposite side can be included in the design. Adding this type of gusset to the tube design reduces
the beam deflection and the stress when compared to the design without any gusset (s). The
variable “t” is defined as the width of the structural tube that the gusset is strengthening. For a
square tube this is easily defined. However, for a rectangular structural tube, “t” is defined as the
width of the tube that the gusset is being attached to.
Standard Gusset Design

Section 7
7.12.2. Gusset Design for Cantilever Tube Construction

Tube (beam) designs that result in cantilever loads require additional structural support compared
to the standard construction. This design minimizes the deflection of the cantilever beam and
transfers the stress away from the welded tube joint. As with the standard gusset design, add the
second gusset to this type of tube design when additional support is required. The square side of
the gusset should be welded to the structural member as shown below. As above, “t” is the width of
the structural tube that is being strengthened.
Cantilever Tube Gusset Design

Below are two examples of acceptable gusset reinforcement for a plate to a tube. The example on the
left results in a stronger joint.

Section 7
Preferred: Optional: Not for use in high-

load, non-static applications:
7.13. Pierce Unit Mounting

Pierce units and other heavy mechanisms that require precise location shall be mounted with jackscrews
and grind spacers as shown in the example below.
Y
X

Section 7
7.14. Weld Gun Mounting (Incline Adjustment)

When fixture weld guns are mounted to various platforms, tool base, riser brackets, etc, there could be
instances where adjustments may be difficult or hazardous to achieve based upon gravity conditions.
The example below may provide the capability to make such adjustments if warranted.

Section 7

GMD1 - Section 07 - Tool Frames, Bases, and Robot Interface Equipment (Update 31JA22)

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Global Mechanical Design Standards GMD1

Tool Frames, Bases, and Robot Interface Equipment

7. Tool Frames, Bases and Robot Interface Equipment

Geopallet Example: GEO Fixture Example:

Tool Frames, Bases, and Robot Interface Equipment

7.2.1. Custom Frames and Bases (Preferred - LEAN Solution)

Hoist Ring Hole

Example of a Custom Tool Base

Tool Frames, Bases, and Robot Interface Equipment

Tool Frames, Bases, and Robot Interface Equipment

7.2.2. Frames or Bucks (Preferred - LEAN Solution)

7.2.3. NAAMS Bases (Alternative)

Tool Frames, Bases, and Robot Interface Equipment

7.2.4. NAAMS Heavy Duty Bases (Alternative – Not Lean)

Tool Frames, Bases, and Robot Interface Equipment

7.3. Base Transportation

7.3.1. Integral Transportation Designed into Frame

7.3.2. Hoist Rings

HOIST RING (4 PLACES)

CHAIN, SLING, ETC.

HOIST RING SIZE TO BE

VIEW IN DIRECTION OF ARROW "A"

Tool Frames, Bases, and Robot Interface Equipment

Example of a Custom Tool Base

Tool Frames, Bases, and Robot Interface Equipment

7.3.3. Fork Pockets

FORK POCKET FORK POCKET

Fork pocket Designs for a maximum of

FORK POCKET FORK POCKET

Fork pocket designs for tools over

Tool Frames, Bases, and Robot Interface Equipment

7.4. Precision Finishing

Tool Frames, Bases, and Robot Interface Equipment

7.5. Controls Equipment for Production Frames and Bases

Any deviation requires the GM Manufacturing Engineer’s approval.

Tool Frames, Bases, and Robot Interface Equipment

Tool Frames, Bases, and Robot Interface Equipment

Tool Frames, Bases, and Robot Interface Equipment

7.7. Weld Washers and Coordination Holes for Bases

Symmetrical tools / bases

Tool Frames, Bases, and Robot Interface Equipment

Do not finish surfaces where non-critical tooling exists.

ACTUAL MEASURED VALUE

COORDINATION HOLE (REF.)

HOLE SIZE = 12mm F7

Tool Frames, Bases, and Robot Interface Equipment

7.8. Leveling and Anchorage

If a tool is NOT certified, no leveling feet are required.

7.8.1. Low Profile Bases - C-Flex Group

The application of a Low Profile Base is approved by the GM Manufacturing Engineer.

Low Profile Base design guidelines:

• Base plate after machining is a minimum of 32mm thick.

Tool Frames, Bases, and Robot Interface Equipment

Top of Base Tooling on Top of Base

Set Screw Set Screw below flush

Reference this section for guidelines to locate on Low Profile bases.

Tool Frames, Bases, and Robot Interface Equipment

7.9. Robot Adaptor Plates, Base Plates, and Risers

Tool Frames, Bases, and Robot Interface Equipment

7.9.1. Robot Cable Support

Tool Frames, Bases, and Robot Interface Equipment

7.9.2. Robot 7th Axis Floor Clearance